Method and apparatus for creating pouches or bags with multiphase sealing

ABSTRACT

A method and apparatus for forming pouches and/or bags is disclosed. A seal and/or insert is crushed using a multiphase sealer or crusher.

RELATED APPLICATIONS

This is a division of, and claims the benefit of the filing date of U.S.patent application Ser. No. 15/374,060, filed on Dec. 9, 2016, which isa continuation in part of, and claims the benefit of the filing date of,U.S. Provisional Patent Application No. 62/265,639, filed on Dec. 10,2015, which is a continuation in part of, and claims the benefit of thefiling date of, U.S. Provisional Patent Application No. 62/265,632,filed on Dec. 10, 2015.

FIELD OF THE INVENTION

The present disclosure relates generally to the art of making pouches orbags, and more particularly to the art of making pouches or bags using amultiphase sealer.

BACKGROUND OF THE INVENTION

There are many known stand up pouch machines, and this invention will beexplained in the context of pouch machines such as the CMD® Stand-UpPouch Machine® or that shown in U.S. Pat. Nos. 6,976,946, 7,191,575 and7,325,379, each of which are hereby incorporated by reference, and USPatent Publications US-2014-0332138-A1 and US-2011-0207589-A1, each ofwhich are also hereby incorporated by reference. One example of a priorart pouch machine with a zipper crush section includes an unwind orinfeed section, followed by a forming or folding section, followed by amachine direction bottom seal and zipper flange sealing section,followed by a zipper crush section, followed by a side sealing section,followed by other processes such as cut off, hole punch, etc. The filmis advanced and stopped, and each section operates on the portion of thefilm in that section. Then, when the operations are complete, the filmis advanced, and each section again operates. When the film hascompleted the path through the machine each operations has beenperformed on the film, thus creating the pouch.

Pouch design have become complex, such as having any of a number offeatures, including closable zippers, easy open tear strings, productprotecting venting, etc. These features are added with insert materialor materials that are different than and/or have a different thicknessthan the pouch body or substrate material. Insert, as used herein,refers to a feature such as a closure (zipper, hook and loop, press toclose, etc), a tear strip, a vent, plugs, valves, spouts, strips, etc.that are comprised of materials different than and/or have a differentthickness than the materials comprising the pouch body or substrate.

An insert, such as a zipper, is typically provided as a continuous strip(or strips) which must be compressed (crushed) and sealed to the pouch.The portion of the zipper near the edge of the pouch must be sealed toproperly seal the pouch. The prior art machines were costly to operateand often made poor seals around the insert and/or took too much time.

It is difficult to crush and seal inserts to the substrate because theinsert or zipper is thicker than the pouch, and comprised of a differentmaterial. Creating consistently strong seals requires the sealingpressure be uniform across the length of the seal and the additionalthickness of the insert material causes inconsistent pressure in theseal area.

The prior art typically sealed the edge of the zipper/pouch by eithercrushing it with a modified sealer (called a zipper crush or zippercrush sealer), or heating it with ultrasound. Crushing the zipperminimizes the seal pressure differences along the length of the sideseal. If inserts are not sufficiently crushed there will be insufficientpressure to create a seal between the pouch substrates were itintersects the insert material FIG. 1 shows a cross sectional view of azipper insert 102 inserted between two layers 104 and 106 of a pouchsubstrate. FIG. 2 shows the zipper insert and substrates after crushing.

Crushing the insert in one step directly from its original thickness tothe final thickness makes it more likely for the seals to be fractured.Thus, prior art machines sometimes included two separatesealers/crushers. The first sealers/crusher crushed the zipper most ofthe way, and the second sealers/crusher crushed the zipper to the finaldesired thickness. Even with two conventional crushing stations, pouchconverters needed to run at slower than desired speeds to create strongseals with zipper material because of fractured seals.

Crushing and sealing the insert requires a heat source, pressure, andtime. The heat source must have enough thermal mass to melt the insertmaterial and enough rigidity to maintain its shape even with significantcrush pressure. A hot bar (sometimes called a seal head or platen) istypically used in the prior art. Most prior art pouch machines usecontinuous pressure systems to crush insert materials. These crushingunit are typically adaptations of a cross seal head station. Pneumaticcylinders, or springs are used to create the continuous pressure (eitherconstant or gradually changing), and utilize heaters and tooling smallerthan the cross sealers. This method is effective to flatten the insertbut can create fractured seals and/or poor bond strength between theinsert and substrate and/or between the insert materials. Seal heads canbe driven with a servomotor and eccentric linkage, but this approach ismore expensive than continuous pressure systems.

Prior art continuous crush pressure systems do not always provideconsistent seal bond strengths. Crushing pressure is nominally constantwith slight variations and is uncontrolled, open loop, and thecontinuous crushing force creates and maintains shear and stain stress.Shear stress is a force perpendicular to the crushing force and parallelto the plane created by difference in flow rates. Strain is created byintermolecular mechanical obstruction and friction, and is dependent onpressure and temperature.

Crush rate and final head position are determine by equilibrium—when thecrushing pressure equals the shear resistance of material the head willstop. Therefore seal shear stress and intermolecular stress areconsiderable higher than desirable. Crystalline sections of the polymerchain may not uncoil and relax into their new position because thecrushing force adds more intermolecular stain. If the amorphous sectionsare orientated in a direction not conducive to entangling, the crushingforce will maintain strain and prevent further entanglement. This meansoriented amorphous sections are unable to properly entangle due to thecontinuous crush pressure and stress it creates, and the crystallinesection can spring back causing shear on the seal.

Prior art crush systems are limited in performance and cannot beoptimized for seal strength and run rate. Running lower crush pressurewill improve seals, but will require longer cycle time, which can limitmachine run rates. Cycle rate can be minimized with higher pressures,but at the cost of higher shear and stain, and lower seal bond strength.

Accordingly, a machine and method to make pouches with inserts or makebags with seals that can consistently and economically create qualityseals in a timely fashion without creating undue seal shear stress andintermolecular stain, is desired.

SUMMARY OF THE PRESENT INVENTION

According to a first aspect of the disclosure a pouch machine has aninsert crush station with a multiphase crusher that receives an insertand a substrate.

According to a second aspect of the disclosure a pouch machine has aninsert crush station that includes a controller with includes at leasttwo of a pre-crush heating module, a controlled crushing module, and acrush setting module, that are consecutively operated.

According to a third aspect of the disclosure a method of making pouchesincludes feeding a substrate to an insert crush station, feeding aninsert to the insert crush station, multiphase crushing of the insertand substrate and forming seals to create a pouch.

According to a fourth aspect of the disclosure a method of makingpouches includes feeding a substrate to an insert crush station, feedingan insert to the insert crush station, and controlling an insert crushstation to consecutively provide at least two or three of a pre-crushheating, a controlled crushing, and a crush setting of the insert andsubstrate.

The insert crush station includes a platen with a controller, and thecontroller has two or all of a pre-crush heating module, a controlledcrushing module, and a crushing module that operate consecutivelywithout returning to a home position between their operation, in onealternative. Platen, as used herein, refers to a bar, plate, or otherdevice that is used to form a seal or to apply pressure and heat to asubstrate and/or substrate and insert.

The insert crush station includes a servo motor operatively connected tomove a multiphase platen in response to the controller, and an eccentriclinkage and/or a screw driven actuator are connected to the platen andservo motor, to translate motion of the servo motor to motion of theplaten in another alternative.

The eccentric linkage is active between 175 and 180 degrees from topdead center in another alternative.

The multiphase crusher includes a heat source but does not include anultrasound source, and/or the pouch machine includes a second sealingstation that forms a seal pattern to form a pouch, in one embodiment.

The insert is a zipper strip, a tear strip, and a vent strip, a press toclose zipper strip, a hook and loop strip, a tear tape strip, and a plugand valve strip in various embodiments.

The pouch machine includes a second insert crush station that receivesthe substrate and insert in one alternative.

The pouch includes a controller with a distance module in oneembodiment.

Other principal features and advantages of will become apparent to thoseskilled in the art upon review of the following drawings, the detaileddescription, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is cross section of a zipper insert and a pouch substrate priorto crushing/sealing;

FIG. 2 is cross section of a crushed/sealed zipper insert and a pouchsubstrate;

FIG. 3 shows travel and eccentric motion for an eccentric linkage;

FIG. 4 shows travel and eccentric motion in the crush area for aneccentric linkage;

FIG. 5 shows a graph of a multi phase crush;

FIG. 6 shows an insert after flowing during the preheat and crush;

FIG. 7 shows three polymer entangling their chains;

FIG. 8 shows temperature versus depth into polyethylene for variousdwell times;

FIG. 9 is a block diagram of a pouch machine;

FIG. 10 is a block diagram of part of a controller for pouch machine;

FIG. 11 is a sela head, seal bar, or platen; and

FIG. 12 is a block diagram of a bag machine.

Before explaining at least one embodiment in detail it is to beunderstood that the invention is not limited in its application to thedetails of construction and the arrangement of the components set forthin the following description or illustrated in the drawings. Theinvention is capable of being implemented with other embodiments or ofbeing practiced or carried out in various ways. Also, it is to beunderstood that the phraseology and terminology employed herein is forthe purpose of description and should not be regarded as limiting. Likereference numerals are used to indicate like components.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

While the present disclosure will be illustrated with reference to aparticular implementation it should be understood at the outset that thepouch machine and method of making pouches can be implemented with otherdesigns, components, and actions.

Generally, the method for making pouches includes multiphase crushing aninsert, and the machine for making pouches includes an insert crushsection that has a multiphase crusher. The section applies a multiphasecrush to crush/seal an insert in multiple phases. The multiphase crushis performed by a single station. Additional crush stations may be used,but at least one station performs a multiphase crush. Other than themultiphase crushing, the machine and method can be consistent with theprior art. Single station, as used herein, refers to a location where aseal is formed or partially formed, without advancing the film toanother location. Prior art zipper crush often used multiple stations,wherein the seal was partially formed at one station, then the filmadvanced and the seal was completed at a second station. One embodimentprovides for multiphase sealing a bag.

Insert crush station, as used herein, refers to a station that appliesenergy to crush an insert and substrate to seal the insert to the pouchand/or film used to form the pouch. An insert crush section (or station)is a type of seal section. Multiphase crush, as used herein, refers to acrush performed by a platen or seal bar, wherein the crush has at leasttwo phases, such as at least two of pre-crush heating (also calledpre-crush phase or pre-heating phase), controlled crushing, andcrushing. Multiphase crusher, as used herein, refers to a crush stationthat provides a multiphase crush (which can be heat or ultrasonic).Multiphase crushing, as used herein, refers to performing a multiphasecrush.

The pouch machine preferably includes a controller that has modules tocontrol each phase of the insert crush. The preferred embodimentprovides that the controller include a pre-crush heating module thatcauses a platen to move in a pre-crush heating phase, a controlledcrushing module that causes the platen to move in a controlled crushphase, and a crush setting module that causes the platen to move in acrush setting phase.

Controller, as used herein refers to the circuitry and software thatcontrols operation of one or more of a pouch machine, sections of apouch machine, or portions of a section of a pouch machine, and caninclude built-in controllers such as a controller that comes with aservo motor, and can be in a single location, or distributed overmultiple locations. Control module or module, as used herein refers tosoftware and circuitry that cooperate to perform one or more definedfunctions, and control hardware and software can be part of multiplemodules.

Pre-crush module, as used herein refers to a control module that causesa multiphase sealer to include a pre-crush motion profile—that is amotion profile that results in pre-crush heating an insert beforeapplying significant crush pressure to the insert. A pre-crush motionprofile starts heating the surfaces and provides a more uniformtemperature profile to lower intermolecular strain and seal shearstress. Pre-crush heating, as used herein, refers to heating a materialto be crushed before applying crush pressure.

Controlled crushing module, as used herein refers to a control modulethat causes a multiphase sealer to include a controlled crush motionprofile—that is a motion profile that results in a controlled crush rateand pressure. Controlled crushing, as used herein, refers to crushing aninsert at a controlled crush rate and pressure.

Crush setting module, as used herein, refers to a control module thatcauses a multiphase sealer to include a crush setting motionprofile—that is a motion profile that results in heating with molecularrelaxation and without additional pressure beyond that created by thecrushing motion. A crush setting motion profile allows the displacedmolecules to relax, and/or reduces intermolecular strain, which aids inthe crushed material holding its new shape, and reduces the likelihoodthat the material springs back creating seal shear stress. Crushsetting, or setting a crush, as used herein refers to heating an insertto obtain molecular relaxation and without additional crush pressure toallow displaced molecules to relax, and/or reduce intermolecular strain.

The preferred embodiment will be described with respect to a zipperinsert and a zipper strip. Alternative embodiments provide for any typeof insert, including hook and loop closures, press to close closures, atear strips, vents, plugs, valves, spouts, strips, etc. Insert, as usedherein, refers to a feature such as a such as a closure (zipper, hookand loop, press to close, etc), a tear strip, a vent, plugs, valves,spouts, strips, etc. that is comprised of materials different from, orhaving a different thickness than, the materials comprising the pouchbody or substrate. Insert strip, as used herein, refers to a strip ofinserts. Tear strip, as used herein refers to an insert strip used tocreate a tear strip as part of a pouch. Vent strip, as used hereinrefers to an insert strip used to create a vent as part of a pouch.Zipper strip, as used herein refers to an insert strip used to create azipper as part of a pouch.

The preferred embodiment provides that the film or substrate follow afilm path including (in this order) an unwind or infeed section,followed by a forming or folding section, followed by a machinedirection bottom seal and zipper flange sealing section with a zipperinfeed to provide the zipper strip, followed by a zipper crush section,followed by a side sealing section, followed by other processes such ascut off, hole punch, etc. Side seals refer to the seals that typicallyextend vertically along the side of the pouch when the pouch isstanding. The flange of the zipper is sealed to the pouch—the zipper issealed to the pouch across what will be horizontal and near the top whenthe pouch is upright and in use (standing). Alternative embodiments havethe zipper (or other insert) in different locations. The zipper iscrushed where the zipper is in the side seal region using the multiplephases described herein. Typically between one and five cross seals areused to form the sides of the pouch. Every action except the zippercrush can be consistent with the prior art.

The zipper crush includes a motion/heating profile of lowering theplaten providing the zipper crush to a first position where the zipperis contacted with light, non-crushing pressure, thus preheating thezipper (the precrush phase). Then, the platen is lowered to a crushed orcrushing position (the controlled crush phase), and the platen dwells inthe crushed position (the crush setting phase). The specific profile canvary with the desired application.

One embodiment provides for a profile shown in FIG. 5 that includes aninitial (no contact) position of 0.165 inches, and rapidly lowering thesealer 0.125 inches from the initial position to 0.04 inches (in 90msecs), where it contacts the zipper. The distances described hereinvary with material type and thickness, and are merely exemplary. Thisposition is held for 30 msecs in the preheat phase. Then the sealer islowered 0.02 inches over the next 80 msec while the zipper is beingcrushed, Next, the sealer is held at the same distance for 40 msec whilethe crush is setting (the crush setting phase). The sealer then rapidlyreturns to the starting position.

Alternative profiles include maintaining the initial position forbetween 0.01 seconds and 0.0765 seconds, depending on the time needed tocrush the insert. The platen can stop at between 0.001 inches (for nozipper) and 0.012 inches (for a spout), depending on the thickness ofthe insert. The length of time the position is held varies depending onthe material. The time should be long enough to soften the material soit won't fracture in the crushing phase. Thicker material requires moretime. The sealer is lowered an amount depending on the materialthickness and type during the controlled crushing phase. Over the next80 msec while the zipper is being crushed, Next, the sealer is held atthe same distance for 40 msec while the crush is setting (the crushsetting phase). The sealer then rapidly returns to the startingposition.

Another embodiment provides for a motion profile that includes rapidlylowering the sealer 0.2 inches from the initial position, so that itcontacts the zipper. Then, the sealer is lowered 0.05 inches over thenext 25 msec while the zipper is being preheated (in the preheat phase).Alternatives include lowering the sealer 0.005 inches, or not loweringit at all in this phase or stage. The sealer is then lowered another0.25 inches over the next 50 msec which crushes the zipper (in the crushphase). Alternatives provide for lowering the sealer 0.05 inches in thisstage. The sealer then dwells at the crush height for 25 msec (in thecrush setting phase), and then rapidly returns to the starting position.

The multiphase crushing enhances side seal bond strengths by reducingintermolecular strain and seal shear. During the pre-crush heating phasethe insert material is heated without pressure, and starts heating thesurfaces. Additionally this “pre-crush heating” provides a more uniformtemperature profile which lowers intermolecular strain and seal shearstress.

During the controlled crush phase seal strength can be optimized bybalancing heat transfer and molten material flow/displacement and bycontrolling the rate of crush. Balancing heat and mass transfer reducesboth molecular strain and shear stress on the sealing area.

During the crush setting phase, the displaced molecules relax, reducingintermolecular strain. The result is crushed material that is morelikely to hold its new shape. Without this relax phase, the material canspring back creating stresses on the seal.

The multiphase crushing provides a more uniform temperature and flowresulting in lower shear stress, and stronger seals that are less likelyto be fractured than the prior art single phase crushing. Also, thecrush setting phase allows crystalline sections of the polymer chain touncoil and relax into their new position. This is in contrast to theprior art single phase crushing that provided a crushing force thatadded intermolecular stain. When the crushing force is released by thecrush setting phase of this disclosure, the stain stress is reduced, andthe crystalline section will relax and spring back into a mostly crushedposition.

The preferred embodiment uses a zipper/insert crush station having aservo actuated linear screw. The servo motor provides the desired motioncontrol, and the screw translates the servo motion to the linear motiondesired for moving the platen a precisely controlled distance at aprecisely controlled rate, to provide the three phase crush. Theservomotor can easily create the desired three phases during the crushcycle, allowing materials to heat, seal, and flow with reduced shear andstrain. Various embodiment use the linear actuated screw servomotor withor without feedback control.

The preferred motion control provides desired side seal bond strengthsand fewer fractured seals. Because the servomotor and head position aredirectly linked, servomotor error can be minimized and feedback controlis possible. Error is minimized with the use of gearing and the error isuniform though the distance of travel. Using feedback control there isno excessive pressure and small or no air gaps. As the material heatshead displacement and material flow are minimized, reducing shearstress.

The temperature profile through the insert material being crushed is notuniform during the first two phases of the crush motion profile. At anygiven time during the first two phases, and partially into the thirdphase, of the motion profile the temperature of some portion of theinsert material nearest the heated crushing die can be as much as 40% to50% above the melt temperature of the insert material. Polymers at thesealing surface are heated close to melt temperature and amorphous chaincan start entangling in the preheat phase. Variations of temperature atthe sealing surface are reduced compared to the temperature variationsproduced by prior art continuous pressure system. Uniform temperaturesof the insert material result in seals that are formed with minimalshear and strain

The preferred embodiment provides a short heating time to allow thematerial temperatures and viscosities to become more uniform and atsimilar rates. As a result, the material flows at a lower temperatureand requires less heat to overcome the shear and strain. FIG. 6 showsinsert 102 flowing as indicated by arrows 602 and 604.

Entangling of the amorphous chains may or may not occur as the insert iscrushed. Because temperature is more uniform, the material flow will besimilar and the seal shear stress will be reduced, which result in lessuntangling. Control of the head allows for seal strength and cycle timeto be optimized by balancing pre-crush heating time, heating bartemperature and crush rate. These settings will changed based onmaterial heat capacity, thermal conductivity, viscosity and volume ofmaterial to displace.

The crush setting phase begins when the platen or head stop at thetarget thickness. Without the crushing force, flow stops and shearstress is eliminated; and intermolecular strain stress dissipates.Molecules can relaxation, allowing crystalline chains to nest, amorphouschains entangle, and sealing occurs. FIG. 7 shows three entangledpolymer chains. The crushed material is more likely to hold its newshape and material spring back can be minimized, along with the shearstress it creates, when the chains are entangled. When the head stops atthe desired position and thickness there is process consistency, andintermolecular strain is minimized along with spring back and sealshear.

During sealing, individual polymer chains stay connected to one anotherfrom intermolecular mechanical entanglement—there is no chemicalreaction or chemical bonding between molecules. In thermal plasticsubstrates, the extrusion process creates entanglement due to time,temperature, and pressure. The degree of entanglement is subject to,among other things, temperature profile, length of barrel, screwgeometry and screw RPM's. Sealing thermoplastics is done by applyingpressure and heat over time, allowing the polymer chains to entangle.Pressure ensures conductive energy transfer and good contact between thesealing surfaces, which allows the chain to entangle. Temperature is ameasurement of molecular energy and vibration; this vibration allows thepolymer chains at the sealing surface to move, expand and entangle withone another. Time is critical to create the vibration and to allowentanglement of chains. The preferred embodiment consistently results inquality seals by providing crush phases that allow for the desirableentanglement.

The particular multiphase profile chosen for a particular applicationshould be such that the crush results in a good temperature distribution(closer to uniform, if possible), with even flow of material. FIG. 8shows temperature of polyethylene for various dwell times and distancesfrom the sealing head. Zero inches is where the head contacts thepolyethelene zipper, and the graph shows temperatures for various depthsinto the zipper.

An alternative embodiment uses a servo motor with an eccentric linkageto move the platen or head to provide the three phase crush. With theservomotor and eccentric linkage embodiment crushing can be delayed andthe rate of crush can be controlled. FIG. 3 shows travel and eccentricmotion for the linkage of this embodiment. Fully retracted correspondsto 100% in FIG. 3. The crush sealer will be open from around 3° to 5°all the way to 100% and back down to 3° to 5°.

The pressure is determined by the thickness of the material and stoppedposition of the platen or sealing head. Pressure increases non-linearlywith rotation of the eccentric, and is typically not monitored orcontrolled. The desired pressure is provided by stopping in the correctposition, and the stopping position is dependent of the rotation of theeccentric via the servomotor. Control of the head or platen position istypically best when the eccentric is 175 to 179.5 degrees from top deadcenter. FIG. 4 shows eccentric motion in the crush area for theeccentric linkage. Fully retracted corresponds to 100% in FIG. 4. Thecrush sealer will be open from around 3° to 5° all the way to 100% andback down to 3° to 5°.

The anvil is preferably provided with a soft elastomer rubber backing(40 to 60 durometer) to maintain consistent contact across the length ofthe seal area, and to prevent damage from over travel of the crushingdie. Heating will be as desired, without excess pressure to provideconsistent strong seals when the head (and thus the servo) is in theproper position. With this alternative there is pre-crush heating andthe rate of crush can be controlled, but there is not as precisepressure feedback control as with servo motor torque.

A pouch machine in accordance with above description is shown in FIG. 9.The pouch machine includes an infeed section 902, that provides a filmof material or substrate to a forming or folding section 904. The filmfollows a film path from forming or folding section 904 to a machinedirection bottom seal and zipper flange sealing section 906. The filmthen follows a path to a zipper crush section 908, that operates asdescribed above. Section 908 is a multiphase insert crushing station. Azipper infeed section 910 (which is part of infeed section 902) providesthe zipper strip to the folded film. A side sealing section 912 isdownstream of zipper crush section 908, and forms the side seals to thepouch.

Other processes such as cut off, hole punch, etc. are performed bysection 914 (and/or additional sections as needed). Additional stationsmay be included prior to or after multiphase insert crushing station908. Section 914 is an outfeed section in one embodiment. Film ofmaterial, as used herein includes the material fed to a pouch machinethat is used to form the pouch and includes laminates, single layerfilms, and multiple layer films. Infeed section, as used herein refersto the section of a pouch machine that feeds the film of material and/orinsert to machine sections that act on the film to form the pouch.Sealing section, as used herein refers to a section of a machine whereat least some of the seals used to form a pouch are imparted.

Multiphase insert crushing station 908 includes, as described above, amultiphase platen or seal head 1100 (shown in FIG. 11) that preferablyprovides a three phase crush. Thus, station 908 is a multiphase sealer.A controller 907 controls each section of machine 900. Multiphase platen(or multiphase seal head), as used herein refers to a platen or sealhead that forms a seal with a motion profile that includes multipleslopes after the material being sealed is contacted, and/or multipledwell distances after the material being sealed is contacted. Multiphasesealer, as used herein refers to a sealer that forms a seal with amotion profile that includes multiple slopes after the material beingsealed is contacted, and/or multiple dwell distances after the materialbeing sealed is contacted.

FIG. 10 shows a block diagram of portions of controller 907, that form amultiphase module that controls the motion of the platen in station 908.The multiphase module includes a pre-heating or pre-crush module 1002.After pre-heating module 1002 acts to control the platen or seal head toprovide the preheating phase, a controlled crushing module 1004 acts tocontrol the platent to provide the controlled crush phase. Aftercontrolled crush module 1004 acts to control the platen to providecontrolled crush, a crush setting module 1006 acts to control the platento provide the crush setting phase. A distance module 1008 controls theplaten to move to the desired distance, by providing the desireddistances and/or feedback to the other module. Feedback is shown byarrows 1010. Distance module, as used herein refers to a control modulethat causes a sealer to move a desired distance at a desired speed orspeeds. Multi-phase module, as used herein refers to a control modulethat controls the motion of a sealer and/or platen such that the platenis a multiphase platen and/or sealer. Pre-crushing or pre heating aninsert, as used herein refers to heating an insert before applyingsignificant crush pressure to the insert to provide a more uniformtemperature profile to lower intermolecular strain and seal shearstress.

One alternative provides for using the multiphase station to impart aseal other than for an insert. The multiphase station can make highquality and consistent seals with or without an insert. Anotheralternative provides for a bag machine to have at least some of theseals formed using a multiphase sealer 1204, with at least an upstreaminfeed section 1202, a downstream outfeed section 1206, and a controller1208, as shown in FIG. 12.

Another alternative provides for using ultrasonic energy in themultiphase station to crush the insert. The platen (or other device suchas a head) can apply ultrasonic energy in a multiphase manner to providethe pre-crush, controlled crush, and crush setting phases.

Numerous modifications may be made to the present disclosure which stillfall within the intended scope hereof. Thus, it should be apparent thatthere has been provided a method and apparatus for making pouches with amultiphase insert crush that fully satisfies the objectives andadvantages set forth above. Although the invention has been describedusing specific embodiments thereof, it is evident that manyalternatives, modifications, and variations will be apparent to thoseskilled in the art. Accordingly, the invention is intended to embraceall such alternatives, modifications and variations that fall within thespirit and broad scope of the appended claims.

The invention claimed is:
 1. A method of making pouches, comprising:feeding a substrate to an insert crush station; feeding an insert to theinsert crush station; multiphase crushing the insert and substrate; andforming seals to create a pouch.
 2. The method of claim 1 wherein themultiphase crushing includes at least two of a pre-crush heating, acontrolled crushing, and a crush setting, wherein the at least two ofthe pre-crush heating, the controlled crushing, and the crush settingare consecutive.
 3. The method of claim 2 wherein the multiphasecrushing includes pre-crush heating, controlled crushing, and crushsetting.
 4. The method of claim 2 wherein the insert is a zipper.
 5. Themethod of claim 2 wherein the multiphase crushing includes providingheat and does not include providing ultrasonic energy.
 6. The method ofclaim 2, further comprising controlling a second insert crush stationthat receives the insert and the substrate.
 7. A method of makingpouches, comprising: feeding a substrate to an insert crush station;feeding an insert to the insert crush station; and controlling an insertcrush station to provide at least two of a pre-crush heating, acontrolled crushing, and a crush setting of the insert and substrate,wherein the at least two of the pre-crush heating, the controlledcrushing, and the crush setting are consecutive.
 8. The method of claim7 wherein providing at least two of the pre-crush heating, thecontrolled crushing, and the crushing of the insert and substrate,includes providing the pre-crush heating, the controlled crushing, andthe crush setting.
 9. The method of claim 8, wherein providing an insertincludes providing a zipper.
 10. The method of claim 7, whereinproviding at least two of the pre-crush heating, the controlledcrushing, and the crush setting includes providing heat and does notinclude providing ultrasonic energy.
 11. The method of claim 7 furthercomprising controlling a second insert crush station that receives theinsert and the substrate.